Rope auto spooler machine

ABSTRACT

A rope auto spooler is configured to spool rope onto a cable spool. The rope auto spooler includes a frame, a spool mounting and driving assembly rotatably mounted on the frame around a first axis, the spool mounting and driving assembly configured to mount the spool thereon, a guide linearly translatable along the frame along a second axis, the guide being configured to accept rope therethrough, and a drive apparatus to which the guide is operatively coupled, the drive apparatus configured to linearly translate the guide relative to the frame along the second axis.

This application claims priority to U.S. provisional application Ser.No. 62/246,253, filed on Oct. 26, 2015, the contents of which areincorporated herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a rope auto spooler machine whichautomatically spools rope onto a spool or reel and provides a propertailing force during a cable pull by an associated cable puller.

BACKGROUND

When rope is pulled through conduit, an operator pulls the rope of thetailing end of a rope puller capstan. This rope must be managed and isusually manually wound onto a spool. The prior art uses a manual winchsystem with steel cable, which exert all the forces directly on thespool.

SUMMARY

A rope auto spooler in accordance with some example embodiments isconfigured to spool rope onto a cable spool. The rope auto spoolerincludes a frame, a spool mounting and driving assembly rotatablymounted on the frame around a first axis and configured to mount thespool thereon, a guide linearly translatable along the frame along asecond axis, the guide being configured to accept rope therethrough, anda drive apparatus to which the guide is operatively coupled, the driveapparatus configured to linearly translate the guide relative to theframe along the second axis. The first and second axes extend in thesame direction or in substantially the same direction. In an embodiment,a capstan is additionally provided.

This Summary is provided merely for purposes of summarizing some exampleembodiments so as to provide a basic understanding of some aspects ofthe disclosure. Accordingly, it will be appreciated that the abovedescribed example embodiments are merely examples and should not beconstrued to narrow the scope or spirit of the disclosure in any way.Other embodiments, aspects, and advantages of various disclosedembodiments will become apparent from the following detailed descriptiontaken in conjunction with the accompanying drawings which illustrate, byway of example, the principles of the described embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The organization and manner of the structure and operation of thedisclosed embodiments, together with further objects and advantagesthereof, may best be understood by reference to the followingdescription, taken in connection with the accompanying drawings, whichare not necessarily drawn to scale, wherein like reference numeralsidentify like elements in which:

FIG. 1 is a perspective view of a rope auto spooler machine which has aspool mounted in a vertical orientation;

FIG. 2 is a perspective view of a rope auto spooler machine which has aspool mounted in a horizontal orientation;

FIG. 3 is a perspective view of an alternate rope auto spooler machinewhich has a spool mounted in a vertical orientation;

FIG. 4 is a perspective view of an alternate rope auto spooler machinewhich has a spool mounted in a horizontal orientation;

FIG. 5 is a perspective view of a cable puller which is used with therope auto spooler machine;

FIG. 6 is a perspective view of a drive apparatus of the rope autospooler machine;

FIG. 7 is a perspective view of an alternate drive apparatus of the ropeauto spooler machine;

FIG. 8 is a perspective view of another alternate drive apparatus of therope auto spooler machine;

FIG. 9 is a perspective view of yet another drive apparatus of the ropeauto spooler machine;

FIG. 10 is a perspective view of the rope auto spooler machine showing aspool mounting and driving assembly;

FIG. 11 is a perspective view of the rope auto spooler machine showingan alternate spool mounting and driving assembly;

FIG. 12 is a perspective view of the rope auto spooler machine showingyet alternate spool mounting and driving assembly;

FIG. 13 is a perspective view of the rope auto spooler machine showing afurther alternate spool mounting and driving assembly;

FIG. 14 is a cross-sectional view along line 14-14 of FIG. 13;

FIG. 15 is a perspective view of the rope auto spooler machine showingan even further alternate spool mounting and driving assembly;

FIG. 16 is a perspective view of the rope auto spooler machine showingyet another further alternate spool mounting and driving assembly; and

FIG. 17 is a block diagram of an apparatus that may be implemented onthe rope auto spooler machine.

DETAILED DESCRIPTION

A rope auto spooler machine 20, 20′ automatically spools rope 22 (notshown in FIGS. 1 and 3) onto a spool or reel 24 and provides a propertailing force during a cable pull by an associated cable puller 26, seeFIG. 5. The proper amount of tailing force will stop the rope 22 fromslipping on the cable puller 26 and will produce a sufficient amount ofpulling force to pull in the rope 22 and associated cable (not shown).The rope 22 is neatly wrapped onto the spool 24 by the rope auto spoolermachine 20, 20′. The rope auto spooler machine 20 uses a two-motor axissystem to spool the rope 22; the rope auto spooler machine 20′ uses athree-motor axis system to spool the rope 22. The rope auto spoolermachine 20, 20′ functions as a tensioning device for pulling andautomatically winding the rope 22.

The spool 24 includes a pair of enlarged end flanges 28, 30 having areduced diameter core 32 therebetween. The rope 22 is would around thecore 32 and the enlarged end flanges 28, 30 prevent the rope 22 fromcoming off the ends of the core 32. A central passageway 34 extendsthrough the flanges 28, 30 and through the core 32. The core 32 definesa rotational axis 24 a of the spool 24 which extends along the length ofthe passageway 34.

Attention is invited to the rope auto spooler machine 20 shown in FIGS.1 and 2 which provides a two-motor axis system for pulling andautomatically winding the rope 22 onto the spool 24. The rope autospooler machine 20 includes a frame 36, a rope guide assembly 38 mountedon the frame 36 and which includes a guide 40 which can translaterelative to the frame 36, and a spool mounting and driving assembly 42which is mounted on the frame 36 and is used to mount the spool 24 onthe frame and to rotate the spool 24 relative to the frame 36. The frame36 may be formed of metal as to as to be robust.

The guide 40 translates along an axis 40 a. The direction of therotational axis 24 a of the spool 24 and the direction of the axis 40 aalong which the guide 40 translates are the same such that the axes 23a, 40 a are parallel to one another, or at least substantially alignedsuch that the axes 23 a, 40 a are substantially parallel to one another,in order for the rope 22 to be wound properly on the spool 24. In anembodiment, the rotational axis 24 a of the spool 24 and the axis 40 aalong which the guide 40 fall in a common plane. In an embodiment, therotational axis 24 a of the spool 24 and the axis 40 a along which theguide 40 fall in different planes which are parallel to each other. Inan embodiment as shown in FIG. 1, the spool 24 is vertically mounted onthe frame 36 such that the rotational axis 24 a of the spool 24 and theaxis 40 a along which the guide 40 translates are vertical. In andembodiment as shown in FIG. 2, the spool 24 is horizontally mounted onthe frame 36 such that the rotational axis 24 a of the spool 24 and theaxis 40 a along which the guide 40 translates are horizontal. The axes24 a, 40 a may also be provided at an angle relative to the ground,provided the direction that the rotational axis 24 a of the spool 24 andthe direction that the axis 40 a along which the guide 40 translates arethe same or are substantially the same. The multiple axes minimize theload experienced by the spool 24.

As shown in FIGS. 1 and 2, the frame 36 defines a surface 44 upon whichthe spool 24 is mounted by the spool mounting and driving assembly 42.The rope guide assembly 38 is mounted on the frame 36 proximate to thespool 24 when the spool 24 is mounted on the spool mounting and drivingassembly 42. In FIG. 1, since the spool 24 is vertically mounted, therope guide assembly 38 extends upwardly from the surface 44. In FIG. 2,since the spool 24 is horizontally mounted, the rope guide assembly 38extends parallel to the surface 44.

The rope guide assembly 38 includes a support 46 attached to the frame36, the guide 40, and a drive apparatus 48 including a motor 50 formoving the guide 40 relative to the support 46. The guide 40 isoperatively coupled with the drive apparatus 48. In an embodiment, theguide 40 is directly engaged with the drive apparatus. In an embodiment,the guide 40 is indirectly engaged with the drive apparatus. The driveapparatus 48 is actuated to cause the guide 40 to linearly translaterelative to the support 46 and thus relative to the spool 24.

The guide 40 may take a variety of forms. In an embodiment, the guide 40is formed of a frame 52 having a surfaces 54 a, 54 b mounted thereon;the frame 52 and the surfaces 54 a, 54 b forming a central passageway 56through which the rope 22 can be fed. The rope 22 contacts the surfaces54 a, 54 b which promote the passage of the rope 22 through the guide40. In an embodiment, the surfaces 54 a, 54 b are formed of one or morerollers rotatably mounted to the frame. In an embodiment, the one ormore surfaces 54 a, 54 b affixed to the frame 52 but promote the rope 22sliding over the surfaces 54 a, 54 b by being configured to resistfriction and abrasion of the rope 22; for example, the surfaces 54 a, 54b may be substantially smooth and may be coated with slip promotingmaterial, such as a material sold under the tradename TEFLON. The rope22 contacts the surfaces 54 a, 54 b which promote the passage of therope 22 through the guide 40. A combination of roller(s) and surface(s)which promote sliding may be provided.

The drive apparatus 48 may take a variety of forms.

In an embodiment, as shown in FIG. 6, the drive apparatus 48 includes abelt 58 mounted between two rotatable pulleys 60, 62 which are rotatablymounted on the support 46. Pulley 60 is attached to, and driven by, themotor 50. The guide 40 of this embodiment is attached to the belt 58.When the motor 50 is actuated, the pulley 60 rotates which causes thebelt 58 to travel around the pulleys 60, 62. When the belt 58 travels,the attached guide 40 travels to move the guide 40 in relation to thesupport 46 and to the spool 24.

In an embodiment, as shown in FIG. 7, the drive apparatus 48 includes arail(s) 64 upon which the guide 40 slides. The rail(s) 64 is mountedbetween a motor 50, and the support 46 or between two portions of thesupport 46. The guide 40 of this embodiment is attached to a screw 66which is driven by the motor 50 and may have an opposite end which ismounted to the support 46. As the motor 50 rotates, the screw 66 rotateswhich causes the attached guide 40 to translate in relation to thesupport 46 and to the spool 24.

In an embodiment, as shown in FIG. 8, the drive apparatus 48 includes apiston 68 mounted on the support 46. The guide 40 is attached to thepiston 68. The piston 68 may, for example, be actuated by ahydraulic/pneumatic pump (not shown in FIG. 8) which is driven by themotor 50 (not shown in FIG. 8).

In any of the embodiments shown in FIGS. 6-8, the support 46 may, forexample, be formed as a box-like housing 70 having a slot 72 providedtherethrough. The drive apparatus 48 may be mounted within the box-likehousing 70 and the guide 40 of such embodiments may extend through theslot 72 and outwardly from the box-like housing 70.

In an embodiment, as shown in FIG. 9, the box-like housing 70 has a pairof rails 74 (only one of which is shown) provided thereon which extendin the same direction as the travel direction of the guide 40. A slider76 is mounted on the rails 74 and the guide 40 of this embodimentextends through the slider 76. When the drive apparatus 48 is actuated,the slider 76 moves with the guide 40. The rails 74 and the slider 76provide additional support for the guide 40 during movement.

Attention is invited to FIGS. 10 and 11 which show examples of the spoolmounting and driving assembly 42 for vertically mounting the spool 24 onthe frame 36. The spool 24 seats on the spool mounting and drivingassembly 42.

In an embodiment as shown in FIG. 10, the spool mounting and drivingassembly 42 includes a seat formed as a platform 78 having at least apair of clamps 80 attached thereto and a motor 82 for rotating theplatform 78. The platform 78 is mounted on an axle 82 a of the motor 82and rotates with the axle 82 a. The spool 24 seats on the platform 78such that the enlarged end flange 28 is clamped by the clamps 80 ontothe platform 78. The clamps 80 securely hold the spool 24 on theplatform 78 during rotation of the platform 78, and thus the spool 24,by the motor 82. In an embodiment, the clamp 80 are eliminated and thespool 24 seats on the platform.

In an embodiment as shown in FIG. 11, the spool mounting and drivingassembly 42 includes a seat formed as a platform 84 which has aplurality of freely-rotatable idler rollers 86 mounted thereto and aspindle 88 which extends outwardly from the platform 84. The platform 84is fixed on the frame 36. The spool mounting and driving assembly 42further includes a roller 90 attached to a motor 82 and which is rotatedby the motor 82. The motor 82 is mounted on the frame 36. The spool 24seats on the platform 84 such that the spindle 88 extends through thepassageway 34 and the end flange 28 seats on the idler rollers 86. Theroller 90 engages, or is moved to engagement, with one or both of theend flange 28 and end flange 30. When the motor 82 is driven, the roller90 rotates, which causes rotation of the spool 24 relative to theplatform 84. The idler rollers 86 rotate under the end flange 28 toallow for relative movement between the spool 24 and the platform 84.Additionally, or alternatively, in an embodiment, the motor 82 can beconfigured to rotate one of the rollers 86 to provide rotation to thespool 24.

Attention is invited to FIGS. 12-16 which show examples of the spoolmounting and driving assembly 42 for horizontally mounting the spool 24on the frame 36. The spool 24 seats on the spool mounting and drivingassembly 42.

In some embodiments, such as that shown in FIG. 12, the spool mountingand driving assembly 42 includes spaced apart, vertical support walls92, 94 which extend upwardly from the frame 36. A roller 96 is rotatablymounted between the support walls 92, 94 and is driven by a motor 82. Anidler roller 100 is rotatably mounted between the support wall 92, 94.The spool 24 seats between the rollers 96, 100, such that the rollers96, 100 form a seat for the spool 24. When the motor 82 is driven, theroller 96 rotates, which causes rotation of the spool 24, which in turncauses rotation of the idler roller 100.

In some such embodiments, such as the embodiment illustrated in FIG. 12,each support wall 92, 94 has an elongated slot 96 having a plurality ofspaced apart openings 98 extending downwardly therefrom to enableadjustment of the position of the idler roller 100 relative to thesupport walls 92, 94 for accommodation of various sizes of the spool 24.In this regard, the idler roller 100 of such embodiments may seat withinaligned openings 98 and the idler roller 100 can be moved to differentpositions relative to the support walls 92, 94 by moving the idlerroller 100 along the slot 94 to reposition the roller 100 into a newopening 98 so as to position the idler roller 100 into an engagingposition with the end flanges 28, 30 of the spool 24.

In an embodiment as shown in FIG. 13, the spool mounting and drivingassembly 42 includes vertical support walls 102, 104 extending upwardlyfrom the frame 36 which are spaced apart by vertical end walls 106, 108extending upwardly from the frame 36. At least a pair of freelyrotatable idler rollers 110, 112 are mounted between the support walls102, 104. In an embodiment, the idler rollers 110, 112 are mounted tothe support walls 102, 104 by their shafts engaging through the supportwalls 102, 104; in an embodiment, the idler rollers 110, 112 are mountedto the support walls 102, 104 by their shafts engaging within recessesin the upper surfaces of the support walls 102, 104. In an embodiment,the walls 102, 104, 106, 108 form the outside surfaces of a block whichhas a top surface with recesses therein in which the idler rollers 110,112 seat. In any of the embodiments, the idler rollers 102, 104 rotaterelative to the walls 102, 104, 106, 108. The spool 24 seats on theidler rollers 110, 112 such that the rollers 110, 112 form a seat forthe spool 24. The spool mounting and driving assembly 42 furtherincludes a roller 116 having an engagement 118 attached to an endthereof. The engagement 118 is affixed to the flange 28 of the spool 24such that rotation of the roller 116 causes rotation of the spool 24.The roller 116 forms a seat for the spool 24. In an embodiment, theengagement 118 is teeth, a clamp, an expanding collet, or a combinationthereof. In an embodiment, such as that shown in FIG. 14, the engagement118 may have two parts 120, 112; one part 120 of which is outside of theflange 28 and the other part 122 of which seats within the passageway 34and connects to the first part 120 to secure the flange 28 therebetween.The spool mounting and driving assembly 42 of some embodiments furtherincludes a pulley 124 mounted on the opposite end of the roller 116, abelt 126 extending around the pulley 124 and further extending around apulley 128 which is mounted on the axle 82 a of a motor 82. When motor82 is driven, the roller 128 rotates, causing rotation of the belt 126,causing rotation of the roller 116 and the attached spool 24.

In an embodiment as shown in FIG. 15, the spool mounting and drivingassembly 42 includes the roller 116 having the engagement 118; theroller 116 being cantilevered from an upstanding portion 130 extendingupwardly from the frame 36, and a motor 82 for rotating the roller 116.When the motor 82 is driven, the roller 116 rotates, causing rotation ofthe attached spool 24.

In an embodiment as shown in FIG. 16, the spool mounting and drivingassembly 42 includes an idler roller 132 which is cantilevered from anupstanding portion 134 extending upwardly from the frame 36. The spoolmounting and driving assembly 42 further includes a roller 136 mountedon an axle 82 a of a motor 82. The spool 24 is mounted on the idlerroller 132 by the idler roller 132 passing through the passageway 34 ofthe spool 24. The roller 132 forms a seat for the spool 24. The flange28 engages with the roller 136. When motor 82 is driven, the roller 136rotates, causing rotation of the spool 24 around the roller 132.

The motor 50 for driving the drive apparatus 48 and the motor 82 fordriving the spool mounting and driving assembly 42 may, for example beembodied as a gear motor, a brushless DC servo motors, a PermanentMagnet DC (PMDC) motor an AC induction motor with modulated controlsignal and switches to control speed and direction of rotation, somecombination thereof, or the like. In some embodiments, the motor 50and/or motor 82 may include an on-board motor controller, which maycontrol operation of the motors 50, 82, and which may form part ofand/or interface with the apparatus 400 (e.g., the processing circuitry410 and/or motor control module 418 of the apparatus 400) illustrated inand described with respect to FIG. 17. The motors 50, 82 may be incommunication with each other and/or may be indirectly interfaced viaand controlled by control circuitry, such as may be provided by theapparatus 400 (e.g., the processing circuitry 410 and/or motor controlmodule 418 of the apparatus 400), in order to coordinate movementbetween the drive apparatus 48 and the spool mounting and drivingassembly 42.

In use, the tailing end of the rope 22 which extends from the cablepuller 26 is fed through the central passageway 56 of the guide 40 andwrapped around the spool 24. The motors 50, 82 are then actuated tocause the spool 24 to rotate and the guide 40 to linearly translate. Asthe spool 24 rotates and as the guide 40 linearly translates, the rope22 is wound around the spool 24. Rotation of the spool 24 providestension to pull the rope 22 off the tailing end of a capstan 58 of thecable puller 26. The rope 22 travels through the central passageway 56of the guide 40 which guides the rope 22 to line neatly next to itselfon the spool 24 as the guide 40 linearly translates relative to thesupport 46. The guide 40 can translate back and forth relative to thesupport 46. The motor control module 418 is configured to sense thespeed of the motor 82 or motors 50, 82 and adjust the speed of the motor82 or the motors 50, 82 to provide an appropriate level of tension onthe rope 22.

Attention is invited to the rope auto spooler machine 20′ shown in FIGS.3 and 4 which provides a three-motor axis system for pulling andautomatically winding the rope 22 onto the spool 24. The rope autospooler machine 20′ shown in FIGS. 3 and 4 is identical to the rope autospooler machine 20 shown in FIGS. 1 and 2, expect for the differencesdescribed herein. Like reference numerals shown in FIGS. 3 and 4 denotelike elements as that disclosed in the rope auto spooler 20 of FIGS. 1and 2.

In this three-motor axis system, a capstan assembly 158 is additionallyincluded. The capstan assembly 158 includes a capstan 160 rotatablymounted on an upstanding support 162 which is attached to the frame 36,and a motor 164 for driving the capstan 160. The capstan 160 has arotational axis 160 a. As shown, the support 162 extends from the frame36 on the same side as where the spool 24 is mounted. The rope guideassembly 38 is between the capstan assembly and the spool mounting anddriving assembly 42. The capstan 160 is spaced from the surface 44 ofthe frame 36. In an embodiment as shown in FIG. 3, the rotational axis24 a of the spool 24 and the axis 40 a along which the guide 40translates are vertical or substantially vertical, and the rotationalaxis 160 a of the capstan 160 is horizontal or substantially horizontal.In an embodiment as shown in FIG. 4, the rotational axis 24 a of thespool 24 and the axis 40 a along which the guide 40 translates arehorizontal or substantially horizontal, and the rotational axis 160 a ofthe capstan 160 is horizontal or substantially horizontal. The axes 24a, 40 a, 160 a may also be provided at an angle relative to the ground,provided the direction of the rotational axis 24 a of the spool 24, thedirection that the axis 40 a along which the guide 40 translates, andthe direction of the axis 160 a of the capstan 160 are the same or aresubstantially the same. The multiple axes minimize the load experiencedby the spool 24.

The motor 164 for driving the capstan 160, may, for example be embodiedas a gear motor, a brushless DC servo motor, a Permanent Magnet DC(PMDC) motor, an AC induction motor with modulated control signal andswitches to control speed and direction of rotation, or the like. Insome embodiments, the motor 164 may include an on-board motorcontroller, which may control operation of the motor 164, and which mayform part of and/or interface with the apparatus 400 (e.g., theprocessing circuitry 410 and/or motor control module 418 of theapparatus 400) illustrated in and described with respect to FIG. 17. Themotors 50, 82, 164 may be in communication with each other and/or may beindirectly interfaced via and controlled by control circuitry, such asmay be provided by the apparatus 400 (e.g., the processing circuitry 410and/or motor control module 418 of the apparatus 400), in order tocoordinate movement between the capstan 160, the drive apparatus 48 andthe spool mounting and driving assembly 42.

In use, the tailing end of the rope 22 which extends from the cablepuller 26 is wrapped around the capstan 160, fed through the centralpassageway 56 of the guide 40 and wrapped around the spool 24. Themotors 50, 82, 162 are then actuated to cause the capstan 160 to rotate,the guide 40 to linearly translate and the spool 24 to rotate. The driveapparatus 48 causes the guide 40 to linearly translate relative to thesupport 46 and relative to the capstan 160 and to the spool 24. As thecapstan 160 and spool 24 rotate and as the guide 40 linearly translates,the rope 22 is wound around the spool 24. Rotation of the capstan 160and spool 24 provides tension to pull the rope 22 off the tailing end ofthe capstan 58 of the cable puller 26. The rope 22 travels through thecentral passageway 56 of the guide 40 which guides the rope 22 to lineneatly next to itself on the spool 24 as the guide 40 linearlytranslates relative to the second part 40 of the frame 36. The guide 40can translate back and forth relative to the second part 40 of the frame36. The motor 82 of the spool 24 pulls the rope 22 onto the spool 24.The motor control module 418 is configured to sense the speed of themotor 82 or motors 50, 82 and is configured to adjust the speed of themotor 82 or the motors 50, 82 to provide an appropriate level of tensionon the rope 22. In addition, the motor control module 418 is configuredto sense the speed of the motor 164 and is configured to adjust thespeed of motor 164 to provide a predetermined tension in the rope 22between the capstan 160 and the cable puller 26.

In operation, the rope auto spooler machine 20, 20′ may be positioned onthe floor by resting the frame 36 on the floor. In some deployments, therope auto spooler machine 20, 20′ may be mounted to the floor, such asby bolting the frame 36 to the floor. The frame 36 may have wheels 200,for example see FIG. 13, to support the frame 36 on the floor and toenable the rope auto spooler machine 20, 20′ to be easily moved.Alternatively, the rope auto spooler machine 20, 20′ may be suspendedfrom a ceiling by attaching suitable struts and/or cables to the frame36, or by providing a suspended platform upon the rope auto spoolermachine 20, 20′ is seated.

Attention is invited to FIG. 17 which illustrates a block diagram of anapparatus 400 that may be implemented on the rope auto spooler machine20, 20′ in accordance with some example embodiments. In this regard,when implemented on the rope auto spooler machine 20, 20′, apparatus 400may enable the rope auto spooler machine 20, 20′ to energize and controloperation of motors 54, 56 and motor 164, if provided, in accordancewith one or more example embodiments. In this regard, the apparatus 400may be configured to control operation of motors 54, 56, and/or 164 tosubstantially maintain an appropriate tension on rope 24 so as toprovide proper tailing force and to wind rope 22 on the spool 24 duringa cable pull. It will be appreciated that the components, devices orelements illustrated in and described with respect to FIG. 17 below maynot be mandatory and thus some may be omitted in certain embodiments.Additionally, some embodiments may include further or differentcomponents, devices or elements beyond those illustrated in anddescribed with respect to FIG. 17.

In some example embodiments, the apparatus 400 may include processingcircuitry 410 that is configurable to perform actions in accordance withone or more example embodiments disclosed herein. In this regard, theprocessing circuitry 410 may be configured to perform and/or controlperformance of one or more functionalities of the rope auto spoolermachine 20, 20′, such as to energize and control operation of motors 54,56 and motor 164, if provided, in accordance with various exampleembodiments. The processing circuitry 410 may be configured to performdata processing, application execution and/or other processing andmanagement services according to one or more example embodiments. Inembodiments in which one or more of motors 54, 56, 164 include anon-board motor controller, the processing circuitry 410 may comprise theon-board motor controller(s) and/or may be communicatively coupled withthe on-board motor controller(s) to enable the processing circuitry 410to communicate with and control operation of the motors 54, 56 and motor164, if provided, in accordance with various example embodiments.

In some embodiments, the apparatus 400 or a portion(s) or component(s)thereof, such as the processing circuitry 410, may include one or morechipsets and/or other components that may be provided by integratedcircuits.

In some example embodiments, the processing circuitry 410 may include aprocessor 412 and, in some embodiments, such as that illustrated in FIG.17, may further include memory 414. The processing circuitry 410 may bein communication with or otherwise control a motor control module 418.

The processor 412 may be embodied in a variety of forms. For example,the processor 412 may be embodied as various hardware-based processingmeans such as a microprocessor, a coprocessor, a controller or variousother computing or processing devices including integrated circuits suchas, for example, an ASIC (application specific integrated circuit), anFPGA (field programmable gate array), some combination thereof, or thelike. Although illustrated as a single processor, it will be appreciatedthat the processor 412 may comprise a plurality of processors. Theplurality of processors may be in operative communication with eachother and may be collectively configured to perform one or morefunctionalities of the apparatus 400 as described herein. For example,in some embodiments in which the processor 412 comprises a plurality ofprocessors, the plurality of processors may comprise one or moreon-board motor controllers, such as may be implemented on the motors 54,56 and/or 164 of some embodiments. In some example embodiments, theprocessor 412 may be configured to execute instructions that may bestored in the memory 414 or that may be otherwise accessible to theprocessor 412. As such, whether configured by hardware or by acombination of hardware and software, the processor 412 is capable ofperforming operations according to various embodiments while configuredaccordingly.

In some example embodiments, the memory 414 may include one or morememory devices. Memory 414 may include fixed and/or removable memorydevices. In some embodiments, the memory 414 may provide anon-transitory computer-readable storage medium that may store computerprogram instructions that may be executed by the processor 412. In thisregard, the memory 414 may be configured to store information, data,applications, instructions and/or the like for enabling the apparatus400 to carry out various functions in accordance with one or moreexample embodiments. In some embodiments, the memory 414 may be incommunication with one or more of the processor 412, the user interface416, and the motor control module 418 via one or more buses for passinginformation among components of the apparatus 400.

The motor control module 418 may be embodied as various means, such ascircuitry, hardware, a computer program product comprising a computerreadable medium (for example, the memory 414) storing computer readableprogram instructions that are executable by a processing device (forexample, the processor 412), or some combination thereof. In someembodiments, the processor 412 (or the processing circuitry 410) mayinclude, or otherwise control the motor control module 418. The motorcontrol module 418 may be configured to control the energization of themotor 82 and motor 164 if provided, so that the motor 82 and motor 164,if provided, spins the spool 24 and the capstan 160, if provided, at alevel of rotation to provide an appropriate tension on the rope 22. Themotor control module 418 may be configured to control the energizationof the motor 50 of the guide 40 to move the guide 40 along its path toappropriately wind the rope 22 onto the spool 24. In some exampleembodiments, the motor control module 418 may be configured to controlenergization of one or more of motors 54, 56, and 164 based on inputfrom one or more sensors, which may sense size and status information ofthe rope 22, as described further herein below.

The desired tension provided by the rope auto spooler machine 20, 20′ isdependent upon providing the proper tailing force to the cable puller26. The inner diameter of the rope 22 and the type of rope 22 arelimiting factors for the maximum tension to which the rope 22 can besubjected. The inner diameter of the rope 22 determines how many wrapsof rope 22 can be placed on the spool 24 per revolution of the spool 24.In an embodiment, a user interface 416 may be provided and is incommunication with the processor 412, memory 414, and/or motor controlmodule 418. The user interface 416 may include any user interfaceelement that may enable an operator to input information and/or that maybe used to display operating status information to the operator. By wayof non-limiting example, the user interface 416 may include one or morebuttons, one or more switches, a keypad/keyboard, a display, a touchscreen display, some combination thereof, or the like. An operator mayuse the user interface 416 to input information regarding rope type,rope diameter, spool size, etc. which information may be used by themotor control module 418 to control the energization of the motors 54,56 and motor 164 if provided, so that the motors 54, 56 and motor 164 ifprovided, work in concert. The motor control module 418 may use analgorithm to determine the speed of movement of the guide 40 in relationto the speed of rotation of the spool 24 and the capstan 160, ifprovided. The motor control module 418 may be configured to access(e.g., from memory 414) a table or other structure which stores variousprofiles based on rope type, rope diameter, spool size, etc. and themotors 54, 56 and motor 164 if provided, may be controlled in accordancewith the appropriate profile to maintain proper tension, appropriatelylevel wind the rope, etc.

In some embodiments, the rope auto spooler machine 20, 20′ may includeone or more sensors which may be configured to sense rope size/typeinformation and/or status information (e.g., rope tension) for the rope22. The sensor(s) may be communicatively coupled to the apparatus 400(e.g., to the processor 412 and/or motor control module 418), andinformation received from a sensor(s) may be used by the motor controlmodule 418 to control operation of one or more of motors 54, 56, 164. Inan embodiment, a sensor 500, see FIGS. 1-4, may be provided on the guide40 proximate to the central passageway 56. This sensor 500 detects thepresence of the rope 22 and detects the inner diameter of the rope 22.The processor 412 may generate a warning to the operator when thetension limit of the rope 22 is reached based upon the inner diameter ofthe rope 22 and the type of rope 22. The maximum value for each innerdiameter of the rope 22 and the type of rope 22 is known.

Other sensors (not shown) can be incorporated into the rope auto spoolermachine 20, 20′. Such sensors may be in communication with the processor412 to provide data inputs that may be used for controlling energizationof the motors 54, 56 and motor 164, if provided, as described herein.For example, a limit switch type sensor may be provided to determine theend of travel for the guide 40; a linear displacement sensor may beprovided to determine the outer diameter of the rope 22; a pressuresensor may be used to determine when the guide 40 is in the properlocation with respect to rope 22 on the spool 24. Such a pressure sensormay be mounted on the guide 40. When the rope 22 is fed through theguide 40 and wrapped around the spool 24, when the guide 40 and the rope22 are in the same plane, there will be no force exerted onto guide 40.This will allow the guide 40 to adjust its location to align with thelocation of the current wrap on the spool 24.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which thesedisclosed embodiments pertain having the benefit of the teachingspresented in the foregoing descriptions and the associated drawings.Therefore, it is to be understood that the disclosure is not to belimited to the specific embodiments disclosed herein and thatmodifications and other embodiments are intended to be included withinthe scope of the disclosure. Moreover, although the foregoingdescriptions and the associated drawings describe example embodiments inthe context of certain example combinations of elements and/orfunctions, it should be appreciated that different combinations ofelements and/or functions may be provided by alternative embodimentswithout departing from the scope of the disclosure. In this regard, forexample, different combinations of elements and/or functions than thoseexplicitly described above are also contemplated within the scope of thedisclosure. Although specific terms are employed herein, they are usedin a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. A rope auto spooler configured to spool rope ontoa cable spool, the rope auto spooler comprising: a frame; a spoolmounting and driving assembly configured to mount the spool thereon andconfigured to rotate the spool relative to the frame around a firstaxis, the spool mounting and driving assembly including a seat ontowhich the spool is mounted and a motor configured to rotate the seat; aguide linearly translatable along the frame along a second axis, theguide being configured to accept rope therethrough; and a driveapparatus to which the guide is operatively coupled, the drive apparatusis configured to linearly translate the guide relative to the framealong the second axis.
 2. The rope auto spooler of claim 1, wherein thefirst and second axes extend in substantially the same direction.
 3. Therope auto spooler of claim 2, further comprising a capstan mounted onthe frame and rotatably mounted on the frame around a third axis.
 4. Therope auto spooler of claim 3, wherein the third axis extends in thesubstantially same direction as the first and second axes.
 5. The ropeauto spooler of claim 3, wherein the third axis extends in a differentdirection from the first and second axes.
 6. The rope auto spooler ofclaim 1, further in combination with a cable puller.
 7. The rope autospooler of claim 1, wherein the first and second axes are horizontal. 8.The rope auto spooler of claim 7, further comprising a capstan rotatablymounted on the frame around a third axis.
 9. The rope auto spooler ofclaim 8, wherein the third axis is horizontal.
 10. The rope auto spoolerof claim 1, wherein the first and second axes are vertical.
 11. The ropeauto spooler of claim 10, further comprising a capstan rotatably mountedon the frame around a third axis.
 12. The rope auto spooler of claim 11,wherein the third axis is horizontal.
 13. The rope auto spooler of claim1, further comprising a capstan rotatably mounted on the frame around athird axis.
 14. The rope auto spooler of claim 13, wherein the guide ismounted between the capstan and the spool mounting and driving assembly.15. The rope auto spooler of claim 1, further comprising processingcircuitry configured to control the motor to rotate the seat.
 16. Therope auto spooler of claim 15, wherein the processing circuitry isfurther configured to control the drive apparatus to linearly translatethe guide.
 17. The rope auto spooler of claim 1, wherein the driveassembly includes a second motor.
 18. The rope auto spooler of claim 1,further comprising a sensor mounted on the frame configured to sense thepresence of a rope in the guide.
 19. The rope auto spooler of claim 1,wherein the seat is provided by a platform.
 20. The rope auto spooler ofclaim 1, wherein the seat is provided by a roller.